Introduction to Destructive &

Nondestructive Testing
 DESTRUCTIVE TESTING
• The component is destructed to find out
the mechanical properties like tensile
strength, hardness, impact resistance
fatigue strength etc.
• Renders the material unfit for further
service.
TYPES:
Tensile test
Impact testing
Hardness testing
Micro & Macro examination
 TENSILE TEST

• “Tensile test”- a prepared sample is pulled

until the sample breaks.
 IMPACT TESTING

• An Impact tester uses a heavy pendulum that is able

to measure the amount of force required to shear or
fracture a test sample taken from welds.

• Types;
• Izod – Vertical cantilever type specimen loading
• Charpy – Horizontal beam support loading
(Both methods are similar)
 HARDNESS TESTING

• Hardness may be defined as the resistance to

permanent indentation.

• Three common hardness measuring tests are

– Brinell hardness
– Rockwell hardness test
– Vicker hardness

Hardness tests are performed on the weld

metal, parent metal and heat affected zone in a
weld
 BRINELL HARDNESS TEST

• The Brinell method presses the “indenter”

into a sample for a given period of time.
• The ability for the sample to resist indentation
determines hardness.
 ROCKWELL HARDNESS TEST

• The Rockwell test uses an indenter to

penetrate the surface of the test sample.
• The depth of the indentation determines the
materials hardness on a scale of 0-100
VICKER HARDNESS TESTING
• Vicker Hardness tester uses a square base
pyramidal diamond indenter.
• Load ranges from 1 t0 120kgf and dwell time
is 15 – 20 seconds.
 MACRO EXAMINATION
• on a large scale and can not be observed.
• To check the fusion, penetration and throat
thickness of the weld.
• Specimen is cut from the weld sample, polished and
etched using suitable chemical.
 MICRO EXAMINATION
on a small scale and can be observed
and identified
• To check the microstructure of weld and
parent metal.
• Specimen is finely polished (mirror finish)
and etched using suitable chemical reagent.
 Definition of NDT

Quantitatively measure
some characteristics of
an object.

i.e. Inspect or measure without doing harm.

 Methods of NDT
The
rmo
grap
Visual Micr hy
ow ave
a r ticle
t i ng et ic P
e s Magn
Tap T
Acousti
X-ray c Mi croscop
y
Acoust
ic Emissi en ts t
o n em t ra n
a sur Pe ne
M e iq uid
etic L
Ult agn
ra son M Replication
ic
Lase Eddy
r Inter Curr
Lea kage ferom ent
Fl u x etry
 Uses
of NDE Methods
• Flaw Detection and Evaluation
• Leak Detection
• Location Determination
• Dimensional Measurements Fluorescent penetrant indication

• Structure and Microstructure Characterization

• Estimation of Mechanical and Physical Properties
• Stress (Strain) and Dynamic Response Measurements
• Material Sorting and Chemical Composition
Determination
When are NDE Methods Used?
There are NDE application at almost any stage
in the production or life cycle of a component.
– To assist in product development
– To screen or sort incoming materials
– To monitor, improve or control
manufacturing processes
– To verify proper processing such as heat
treating
– To verify proper assembly
– To inspect for in-service damage
 Six Most Common NDT
Methods
• Visual
• Liquid Penetrant
• Magnetic
• Ultrasonic
• Eddy Current
• X-ray
Visual Inspection
Most basic and common
inspection method.

Tools include
magnifying glasses and
mirrors.

Portable video inspection

unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Robotic crawlers permit
observation in hazardous
or tight areas, such as air
ducts, reactors, pipelines.
 Liquid Penetrant Inspection-
(Surface crack for ferrous and non-ferrous)
• A liquid with high surface wetting characteristics
is applied to the surface of the part and allowed
12-15 min to seep into surface breaking defects.
• The excess liquid is removed from the surface
of the part.
• A developer (powder) is applied to pull the
trapped penetrant out the defect and spread it
on the surface where it can be seen.
• Visual inspection is the final step in the
process. The penetrant used is often loaded
with a fluorescent dye and the inspection is
done under UV light to increase test
sensitivity.
 Rly. Components

• Wheel disc
• Roller bearing
• Yoke
• Draw hook and draft link
• Pistons and Connecting rod
• Co-Co bogie
• Cam and crank shaft
• Reclaimed welding parts.
• Gears
 Magnetic Particle Inspection
• This test is used to detect surface defects as well as sub surface up to 6 mm
depth defects in ferrous materials.
• While the test piece is magnetized, the iron particles will gather at the edges
of the defect (crack or flaw) and can be seen as dark hair line marks with
naked eyes
Magnetic Particle Crack Indications
 Difference b/w MPT &DPT
SN Description MPT DPT
1 Material Ferrous Both
2 Type of defects Surface and sub Surface
surface
3 Time immediately 10-30 min
4 Equipment Magnetizing M/c No m/c reqd.
5 Cost costly Cheaper
6 Temperature Even at higher At room
7 Principle Magnetizing Capillary
8 Corrosion Less Chances are more
9 Residual Present and to be No chance
Magnetism removed
 Radiography
•The test piece is placed in between the
X-ray unit and film.
• X-ray is passed. If there is any hidden
defect that will be seen in the film.
• Defects appear in the same manner
as bone fractures of human beings
appear in X-ray films.
• For more thick plates gamma rays
are used
Radiographic Images
 Rly component
• Engine block
• CoCo bogies
• Pistons
• Castings.
 Eddy Current Testing
Eddy current testing is particularly well suited for detecting
surface cracks but can also be used to make electrical
conductivity and coating thickness measurements. Here a small
surface probe is scanned over the part surface in an attempt to
detect a crack.
Eddy-current testing

Uses electromagnetic induction to detect flaws in conductive

materials for surface crack
 Eddy current
• Defined as a circulating electrical current induced in an
isolated conductor by an alternating magnetic field.
• Eddy current testing is based on the fact that the flow
of eddy currents generates a magnetic field that
opposes the magnetic field developed by the test coil.
• An indicating device connected to a test coil will be
affected by the coil's magnetic field. This field, in turn,
is affected by the eddy current's magnetic field.
• This means that if the flow of eddy current changes,
the indication of the indicating device will also change.
Railway Components
Helical spring & New rails.
 Ultrasonic Inspection

• Our ears have a capacity to hear in a particular

range of frequencies only- this range is sonic,
any thing higher than this range is ultrasonic and
anything below this is infrasonic
• Frequency of sound
Infra sonic Less than 20 Hz
sonic 20 -20,000 Hz-
Ultrasonic More than 20000 Hz
 Common Application of NDT

• Inspection of Raw Products

• Inspection Following Secondary
Processing
• In-Services Damage Inspection
 Ultrasonic Inspection
High frequency sound waves are introduced into a
material and they are reflected back from surfaces or
flaws.
Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
f
showing the depth of features that reflect sound.

initial
pulse

back surface
echo
crack
echo

crack

0 2 4 6 8 10 plate

Oscilloscope, or flaw
detector screen
 Rail Inspection
Special cars are used to
inspect thousands of miles
of rail to find cracks that
may lead to derailment.
Testing of railway components
• Axles
• Wheels
• Rails
• Armature shaft.
• Rail welds
• Bridge girders
• OHE insulators
Periodicity
Rails 12 months
All other 09 months.
 CMT Lab

• Functions of Cmt lab are :

• Failure analysis of broken parts/components
• Testing of locomotive fuel (oil) for usage
• Investigation of unidentified materials ex:lube
oil, fuel oil,etc
• Spectrographic Analysis to give indication
where the particular component is wearing &
proper measure could be taken to rectify it
• Radiator water (Nalco) suitability is done
• Suitability of sand used in loco
 Cont.

• Weld testing
• Rail failure
• Corrosion pattern study
• Plastic material like bushes, pins,are tested
for failure
• Regular testing of wheels, bearings, Springs,
Bogies etc